Threadcutting-Wiley.docVIP

Design of Experiments ?????????????? By: Suresh Subramanian 993 44 4117 Nageswararao Motamarri 993 43 2112 Introduction As a part of the course IEE 572 Design of Experiments, we conducted experiment on external thread cutting operation (Thread Chasing) using a single point cutting tool. When the factors, levels, ranges and response variables selected for the experiment are studied, the reason for the selection of Threading Process becomes obvious. There are several factors affecting the finish of the threads in the threading process, which can be varied easily. They are job speed, depth of cut, threads per inch etc. Factors like operator, machine, coolant flow rate and number of starts can be held constant. There are a host of nuisance factors like job batch, vibration of machine etc., to be taken care of. We have a clear cut, easy to measure response variable – percentage deviation of obtained pitch from the estimated pitch of the threads cut. All of these make thread cutting operation, a good process to analyze. The experiment was conducted on a Center Lathe, provided by IMEL. The measurements of the response variable (pitch of the threads) were measured using a Shadowgraph, provided by Research Lab Services. The experiment is three-factor, three-level with a single replicate. Randomized order of the experimentation was obtained using Design Expert software. The raw material used was soft Aluminum (Grade 361). The threads were manufactured as per the run order, values of pitch of the threads cut were tabulated, percentage deviation was estimated and the results were analyzed using Design Expert. Thread Cutting operation Nomenclature of the thread is explained in the following figure. Lead is the amount a screw thread advances in 360 turn. Pitch is the distance from center to center of two adjacent crests or 5troughs. On the standard single start screw, the pitch and lead are the same. On double or triple start screws, the lead is two or three times the pit